Process for partial oxidation of hydrocarbonaceous fuel and recovery of water from dispersions of soot and water

ABSTRACT

The soot-water dispersion that is produced by quenching and/or scrubbing the raw effluent gas stream from a partial oxidation gas generator in a gas quench cooling and/or scrubbing zone is resolved in a decanter using two different liquid organic extractants. Advantageously, liquid organic by-products from an oxo or oxyl process which may contain harmful water soluble constituents may be used as a major portion of the liquid organic extractant. The dispersion of soot and co-extractants that is produced may be safely disposed of as a portion of the feed to the gas generator without polluting the environment. A novel vertical decanter is provided comprising a vertical cylindrical vessel with separate inner and outer coaxial concentric conduits that pass down through the central axial flanged inlet in the upper head of the vessel. The mixture of soot-water dispersion and first liquid organic extractant i.e. naphtha is passed through the inner conduit and is discharged through a first horizontal radial nozzle located below the interface level. Simultaneously, the second liquid organic extractant i.e. liquid organic by-products from an oxo or oxyl process is passed through the annular passage between the inner and outer conduits and is discharged through a second horizontal radial nozzle located above the interface level. Adjusting means are provided to vary the discharge height of the second horizontal radial nozzle, up or down should there be a change in location of the interface level.

This is a division of application Ser. No. 460,411, filed Jan. 24, 1983now U.S. Pat. No. 4,490,251.

BACKGROUND OF THE INVENTION

This invention relates to the partial oxidation of liquidhydrocarbonaceous fuels including oxygen-containing hydrocarbonaceousfuels. More particularly, it relates to a process and apparatus forresolving the carbon-water dispersion that is produced when the effluentgas stream is quench cooled and/or scrubbed.

The production of synthesis gas, fuel gas, and reducing gas by thepartial oxidation of liquid hydrocarbonaceous fuels is well known. Bythis highly economical process, gas mixtures rich in hydrogen and carbonmonoxide can be produced from hydrocarbonaceous fuels, including lowgrade fuels. The effluent gas stream from the gas generator comprisesH₂, CO, H₂ O; at least one gas from the group consisting of CO₂, H₂ S,COS, CH₄, N₂, and Ar; and about 0.2 to 20 weight percent soot (basisweight of carbon in the feedstock). The effluent gas stream may becleaned and the entrained soot removed by quench cooling and/orscrubbing the gas stream with water. Large volumes of soot-waterdispersion container about 0.5 to 2.0 weight percent soot are therebyproduced. Advantageously by resolving the soot-water dispersion, sootmay be recovered and recycled to the gas generator as a portion of thefeed. Further, water may be recovered and recycled to the gas quenchcooling and scrubbing zones.

A carbon separation process employing a single liquid organic extractantand a bottom fed decanter is described in coassigned U.S. Pat. No.4,014,786, which is incorporated herein by reference. Liquid organicby-products from the oxo or oxyl process are used as extractants incoassigned U.S. Pat. No. 4,016,102, which is incorporated herein byreference.

The liquid organic by-products from the oxo or oxyl process may containup to about 10 wt. % of water soluble fractions. These fractions may beharmful to acid gas solvents or catalysts located in downstreamoperations. Further, clumps or balls of soot may form in the carbonscrubbing equipment when these fractions are present in the scrubbingwater.

By the subject invention, the by-products from the oxo or oxyl processmay be used as the major portion of the extractant for the carbonextraction process, without contaminating the recycled water with thewater soluble fraction. Further, a vertical decanter is provided thatincludes a mechanism for adjusting the inlet distributor for thesecond-stage introduction of the by-products of the oxo or oxyl process.By this means, the location of the inlet distributor for thesecond-stage extractant may be changed to compensate for anyfluctuations in the location of the interface level. Smooth operation ofthe decanter is thereby assured.

SUMMARY OF THE INVENTION

The soot-water dispersion that is produced by quenching and/or scrubbingthe raw effluent gas stream from a partial oxidation gas generator in agas quench cooling and/or scrubbing zone is resolved in a noveltwo-stage vertical decanter using two different liquid organicextractants. A mixture of soot-water dispersion and a first waterimmiscible liquid organic extractant i.e. naphtha is introduced into thedecanter below the interface level. Simultaneously, the second liquidorganic extractant comprising a mixture of the liquid organicby-products from an oxo or oxyl process is introduced into the decanterabove the interface layer. The second liquid organic extractantcomprises a major portion of the total amount of extractant and maycontain water soluble constituents which are harmful to downstreamoperations. Soot separates out from the soot-water dispersion and formsa dispersion that floats on the interface level. The interface layer islocated between the top of a pool of clarified water which settles tothe bottom of the vessel, and the bottom of a pool of dispersioncomprising soot and first and second liquid organic extractants whichfloats on the pool of water. The clarified water is removed and at leasta portion is recycled to the gas quench cooling and scrubbing zone.Simultaneously the dispersion of soot and co-extractants is removed andrecycled to the gas generator as a portion of the feed.

A novel vertical decanter is provided comprising a vertical cylindricalvessel with separate inner and outer coaxial concentric conduits thatpass down through the central axial flanged inlet in the upper head ofthe vessel. The mixture of soot-water dispersion and first liquidorganic extractant i.e. naphtha is passed through the inner conduit andis discharged through a first horizontal radial nozzle located below theinterface level. Simultaneously, the second liquid organic extractanti.e. liquid organic by-products from an oxo or oxyl process is passedthrough the annular passage between the inner and outer conduits and isdischarged through a second horizontal radial nozzle located above theinterface level. Adjusting means are provided to vary the dischargeheight of the second horizontal radial nozzle, up or down should therebe a change in location of the interface level.

BRIEF DESCRIPTION OF THE DRAWING

The invention will be further understood by reference to theaccompanying drawing in which:

FIG. 1 is a schematic representation of a preferred embodiment of theprocess. A diagrammatic representation of the decanter in elevation witha fragmented area broken away is also shown.

FIG. 2 is an enlarged vertical view in cross-section of the fragmentedarea of the decanter taken from FIG. 1 and showing the conduitsub-assembly mounted in the upper central axial inlet of the decanter.

DESCRIPTION OF THE INVENTION

The present invention pertains to a process and apparatus forcontinuously resolving the soot-water dispersion that is produced whenhot raw synthesis gas from a gas generator is quench cooled or scrubbedwith water. A novel two-stage decanter is used in the subject processalong with two different liquid organic extractants. Light liquidhydrocarbon fuel is used as the first stage extractant and a mixture ofthe liquid organic by-products from the oxo or oxyl process is used asthe second stage extractant. Further, the novel decanter that is used inthe process may also be used in other processes which employ only asingle liquid organic extractant.

Synthesis gas, reducing gas, or fuel gas is made by the partialoxidation of a hydrocarbonaceous fuel with a free-oxygen containing gasand a temperature moderator in a refractory lined free-flow unpackedsteel pressure vessel such as described in coassigned U.S. Pat. No.3,097,081 issued to DuBois Eastman et al.

The feedstreams are introduced into the reaction zone of the gasgenerator by means of a suitable burner. For example, a singleannulus-type burner such as described in coassigned U.S. Pat. No.2,928,460 issued to DuBois Eastman et al, or a multiple annulus-typeburner as shown in coassigned U.S. Pat. No. 3,705,108 issued to C. P.Marion et al may be used.

The feedstreams are reacted in the gas generator at an autogenoustemperature in the range of about 1500° to 3000° F. and at a pressure inthe range of about 1 to 250 atmospheres. The reaction time in the gasgenerator is about 1 to 20 seconds. The effluent gas mixture leaving thegas generator comprises H₂, CO, H₂ O; at least one gas from the groupCO₂, H₂ S, COS, CH₄, N₂ and Ar; and unreacted soot in the amount ofabout 0.1 to 20 weight percent (basis weight of carbon in thehydrocarbonaceous feed.)

The soot particles entrained in the hot raw effluent gas stream leavingthe gas generator comprises in weight percent carbon 92 to 100, sulfur0.0 to 4.0, and ash 0.0 to 5.0.

The amount of soot in the product synthesis gas may be controlledprimarily by regulating the oxygen to carbon ratio (O/C atom/atom) inthe range of 0.7 to 1.5 atoms of oxygen per atom of carbon in the fuel.The O/C ratio is based upon (1) total of free-oxygen atoms in theoxidant stream plus combined oxygen atoms in the hydrocarbonaceous fuelfeed molecules, including the extractants in the feed, and (2) the totalof carbon atoms in the hydrocarbonaceous fuel feed including theextractants in the feed plus carbon atoms in the recycled particulatecarbon soot. The temperature in the reaction zone may be controlled byregulating the weight ratio of H₂ O to fuel in the range of about 0.15to 3.0.

A wide range of carbon-containing organic materials or hydrocarbonaceousfuels, may be reacted in the gas generator to produce the raw effluentgas. The term "hydrocarbonaceous fuel", as used herein to describevarious suitable feedstocks, is intended to include gaseous, liquid, andsolid hydrocarbons, carbonaceous materials, and mixtures thereof, whichsingly or in admixture with one another are capable of sustaining anautogenous, uncatalized reaction with oxygen to produce the effluent gasstream. For example, there are (1) pumpable slurries of solidcarbonaceous fuels, such as particulate carbon, concentrated sewagesludge, and mixtures thereof in water, oil, or water and oil emulsions;(2) gas-solid suspensions, such as finely ground solid carbonaceousfuels dispersed in either a temperature-moderating gas or in a gaseoushydrocarbon; and (3) gas-liquid-solid dispersions, such as atomizedliquid hydrocarbon fuel and particulate carbon dispersed in atemperature-moderating gas.

The term liquid hydrocarbon, as used herein to describe suitable liquidfeedstocks, is intended to include various materials, such as liquefiedpetroleum gas, crude oil, crude residue, heavy distillates from crudeoil, asphalt, gas oil, tar-sand and shale oil, coal derived oil,aromatic hydrocarbons (such as benzene, toluene, xylene fractions), coaltar, cycle gas oil from fluid-catalytic-cracking operation; furfuralextract of coker gas oil; and mixtures thereof. Gaseous hydrocarbonfuels, as used herein to describe suitable gaseous feedstocks, includemethane, ethane, propane, butane, pentane, natural gas, water gas,coke-oven gas, refinery gas, acetylene tail gas, ethylene off-gas,synthesis gas, and mixtures thereof. Both gaseous and liquid feeds maybe mixed and used simultaneously and may include paraffinic, olefinic,naphthenic and aromatic compounds in any proportion.

Also included within the definition of the term hydrocarbonaceous fuelsare oxygenated hydrocarbonaceous organic materials includingcarbohydrates, cellulosic materials, aldehydes, organic acids, alcohols,ketones, oxygenated fuel oil, waste liquids and by-products fromchemical processes containing oxygenated hydrocarbonaceous organicmaterials and mixtures thereof.

The hydrocarbonaceous feed may be at room temperature or it may bepreheated to a temperature up to as high as about 600° F. to 1200° F.,but preferably below its cracking temperature.

Suitable temperature moderators include H₂ O, CO₂ -rich gas, cooledclean gas from the gas generator or from a gas turbine which may beemployed downstream in the process with or without admixture with air,by-product nitrogen from the air separation unit to be further describedand mixtures of the aforesaid temperature moderators.

The term free-oxygen containing gas, as used herein, is intended toinclude air, oxygen-enriched air, i.e., greater than 21 mole % oxygen,and substantially pure oxygen i.e., greater than 95 mole % oxygen (theremainder comprising N₂ and rare gases). Free-oxygen containing gas maybe introduced into the burner at a temperature in the range of aboutambient to 1200° F.

The hot effluent gas stream from the reaction zone may be quenched inwater in the quench zone. The gas stream is thereby quickly cooled to atemperature in the range of about 180° to 700° F. A suitable quench tankis shown in coassigned U.S. Pat. No. 2,896,927. Alternatively, the hoteffluent gas stream may be passed through a waste heat boiler inindirect heat exchange with water. The cooling water is converted tosteam and the process gas stream is cooled to a temperature in the rangeof about 500° to 900° F. The process gas stream is then scrubbed withwater in a conventional gas scrubbing zone to remove suspended soot andother solid particles.

The pumpable soot-water dispersion obtained from the quench andscrubbing zones contains about 0.5 to 3 weight percent of soot. Further,it is economic to recover and recycle the water in the soot-waterdispersion to the quench tank or scrubbing zone and to recycle therecovered soot to the gas generator as a portion of thathydrocarbonaceous feed. This may be accomplished in the subject process.While the subject process is referred to herein as a two-stage process,actually during the continuous operation both stages are conductedsimultaneously. In the first stage, the soot-water dispersion from thequench cooling and/or scrubbing zone at a temperature in the range ofabout 180° to 700° F., such as about 250° to 550° F. is mixed with afirst liquid organic extractant by means of a suitable conventionalmixer, e.g. mixing valve, static mixer, baffled mixer, pump, orifice,nozzle, propeller mixer, or turbine mixer. High pressure will makepossible the use of an extractant containing lower boiling constituents.High temperatures facilitates phase separation.

The mixed stream is passed into a phase-separation zone, for example adecanter or tank providing a relatively quiescent settling zone. In theseparating zone, also known as a decanter, clarified water falls to thebottom by gravity. Dry-appearing soot particles float to the top of theclarified water along with any excess first stage extractant. The volumeof the settling tank should be sufficient to provide a suitableresidence time for phase separation to occur at a specified flow rate.The residence time for the water phase and the liquid organic extractantphase may be at least 2 minutes, and preferably in the range of about 5to 15 minutes.

The pressure in the settling zone or decanter should be sufficient tomaintain both the extractant and the water in liquid phase, e.g. 5 to250 atmospheres depending upon the temperature. The temperature in thedecanter will be substantially about 150° to 650° F., such as about 200°to 500° F.

The liquid organic extractant used in the first stage may be anypumpable organic liquid which is immiscible with water and for which thesoot has a greater affinity for than it has for water. In addition, thefirst stage liquid organic extractant should contain substantially nowater soluble constituent which would contaminate the water thatseparates from the soot in the decanter. Liquid organic by-products ofthe oxo and oxyl process may contain water soluble constituents whichare harmful to downstream acid-gas solvents or catalysts. Also, thesewater soluble constituents may cause the formation of clumps or balls ofsoot in the decanter or soot scrubbing equipment. Accordingly, suchmaterials are unsuitable for use as the first stage soot extractionmedium. Since substantially all of the water is separated in the firststage of the subject apparatus and process, liquid organic by-productsof the oxo and oxyl process may be safely used as the extractant in thesecond stage.

Suitable first stage liquid organic extractants are light liquidhydrocarbon fuels having an atmospheric boiling point in the range ofabout 100° to 750° F., degrees API in the range of over 20 to about 100,and a carbon number in the range of about 5 to 16. Examples of firststage liquid organic extractants include a light liquid hydrocarbon fuelselected from the group consisting of butane, pentane, hexane, toluol,gasoline, naphtha, and gas oil.

Thus in the first stage, the aforesaid soot-water dispersion is resolvedinto a clarified water layer and particles of dry-appearing soot powderwhich float on the surface of the clarified water. This may beaccomplished by adding the first stage liquid organic extractant to thecarbon-water dispersion in an amount just sufficient to render all ofthe soot hydrophobic but preferably insufficient to produce asoot-extractant dispersion at this point. As a result of this smalleramount of extractant, the soot separates rapidly and substantiallycompletely from the water and floats to the surface of the clarifiedwater layer as a dry-appearing, partially agglomerated soot along withany remaining first stage extractant.

The amount of liquid organic extractant to be added may be obtainedexperimentally by shake tests. Small increments of extractant are addedto the soot-water dispersion until the soot separates rapidly and floatson the surface of the clarified water. Thus when the water phase isclear and the soot is dry-appearing and fluffy, the amount of extractantadded in the first stage will usually fall within the range of 1 to 3times the Oil Absorption No. of the soot in the soot-water dispersion.This amount may range between about 1.5-15 lbs. of extractant per lb. ofsoot or more likely in the range of about 3 to 8. For furtherinformation regarding the test method for determining the Oil AbsorptionNo., see ASTM Method D-281-31.

In the second stage the soot is floated off the surface of the clarifiedwater layer in the decanter by introducing a horizontal stream of secondstage liquid organic extractant into said decanter above the interfacebetween said lower layer of clarified water and an upper layercomprising a dispersion of soot in first stage and second stage liquidorganic extractants.

The amount of liquid organic extractant that is introduced in the secondstage is sufficient to form said soot-co-extractant dispersioncontaining about 0.5 to 9.0 wt. % soot in the total extractant. Thisamount may be about five to ten times the amount of extractant that wasused in the first stage. The clarified water is continuously removedfrom the decanter through an outlet at the bottom of the decanter.Ordinary gaseous materials are then preferably removed from the water ina flash tower. At least a portion of the degassed water i.e. 30 to 100wt. %, such as 50 to 95 wt. % is recycled to the quench tank and/or gasscrubbing zone. Prior to being recycled, the remainder of the degassedwater if any, may be sent to a water treatment facility such asdescribed in coassigned U.S Pat. No. 4,211,646, and which is includedherein by reference.

In the preferred embodiment, the second stage liquid organic extractantis a mixture of the liquid organic by-products from the oxo or oxylprocess. By introducing the second stage extractant into the upperportion of the decanter, above the interface level, the oxo or oxylby-product extractant would have no contact with the water in thedecanter. Accordingly, by the subject process, there would be nocontamination of the water by water soluble constituents in the oxo oroxyl by-product extractant. This process makes feasible the use of theselow value, noxious waste materials as extractants.

Additional advantages are achieved by continuously introducing at leasta portion i.e. 10 to 100 wt. %, such as 50 to 100 wt. % of thedispersion of soot and co-extractants from the upper layer of thedecanter into the partial oxidation gas generator as at least a portionof the fuel feed i.e. 10 to 100 wt. %, such as about 20 to 75 wt. %. Notonly does this serve as a way of getting rid of noxious materialswithout polluting the environment, but feedstock costs are reduced. Inaddition, by recycling the soot-co-extractant dispersion to the gasgenerator as at least a portion of the feedstock, the soot-liquidorganic extractant stripper may be eliminated at a substantial savingsin equipment and energy costs. The stripper i.e. distillation column waspreviously used to recover the organic extractant i.e. naphtha forrecycle to the decanter.

Operating costs for the gas generating phase are also reduced. Theefficiency of the partial oxidation reaction is increased since thecombined oxygen in the oxo or oxyl by-products permits the gasifier tobe run with a reduced amount of free-oxygen containing gas and at areduced temperature. Further, due to the high temperature within thedecanter the decanter serves as a preheater for that portion of thedispersion of soot and co-extractants being fed to the gas generator. Acost savings is also effected by using comparatively low-cost oxo oroxyl by-product material as the second stage extractant in place of theconvnetional light liquid hydrocarbon fuels, such as naphtha.

Emulsion formation is reduced or eliminated by use of the subjectprocess and carbon decanter. This is beneficial because emulsions maylead to poor phase separation and may reduce output.

Thus, when the soot-water dispersion is resolved in the first stage ofthe subject process and the soot floats to the surface of the water, aminimum of extractant is added. Lower grades of first stage extractantmay be used, at a cost savings. When the secondary liquid organicextractant is introduced into the layer of organic liquids in muchlarger amounts, a minimum of mixing takes place. Accordingly, emulsionformation is avoided even if emulsifying agents are present in theextractants.

The oxo process is the commercial application of a chemical reactioncalled oxonation or, more properly, hydroformylation. In this catalyticreaction, hydrogen and carbon monoxide are added across an olefinic bondto produce aldehydes containing one more carbon atom than the olefinicmolecule, and the co-products shown in Table I.

The oxyl process is a method for directly producing alcohols bycatalytically reducing carbon monoxide with hydrogen so as to linkseveral partially reduced carbon atoms together. Essentially it is amodified Fischer-Tropsch Process which preferentially producesoxygenated compounds consisting mainly of alcohols, and the co-productsshown in Table I.

The preferable second stage liquid organic extractant comprises amixture of liquid organic by-products of an oxo or oxyl process andincludes by definition whole samples and fractions thereof. The amountof each constituent in this liquid organic extractant may be taken fromthe ranges shown in Table I.

                  TABLE I                                                         ______________________________________                                        INGREDIENTS IN LIQUID ORGANIC BY-PRODUCTS                                     OF OXO OR OXYL PROCESS                                                        Group           Carbon Range  Wt. %                                           ______________________________________                                        Alcohols        C.sub.3 to C.sub.16                                                                         2 to 75                                         Esters          C.sub.6 to C.sub.28                                                                         5 to 70                                         Aldehydes       C.sub.3 to C.sub.16                                                                         Nil to 25                                       Ketones         C.sub.3 to C.sub.16                                                                         Nil to 25                                       Ethers          C.sub.6 to C.sub.28                                                                         Nil to 50                                       Acids           C.sub.3 to C.sub.16                                                                         Nil to 10                                       Olefins         C.sub.5 to C.sub.15                                                                         Nil to 30                                       Saturated Hydrocarbons                                                                        C.sub.5 to C.sub.28                                                                         Nil to 50                                       Water                         Nil to 15                                       ______________________________________                                    

If a group of compounds is present, there may be more than one compoundin that group present in the extractant. For example, if the liquidorganic extractant contains 65 wt. % of normal and iso alcohols and 18wt. % of esters, then the total remaining constituents in the extractantcannot exceed 17 wt. %. The term by-products includes by definition theliquid organic waste products from the oxo or oxyl process, which havethe composition shown in Table I.

The preferred maximum concentration of organic acid present in theextractant is less than 5 wt. %, for example 1-2 wt. %. For example,after the extractant is added to the carbon-water dispersion the acidcontent of the dispersion may be less than 15 parts per million. Theorganic esters are the reaction products of primary saturated alcoholsand low molecular weight saturated organic acids. Advantageously, it isgenerally unnecessary to purify the second stage extractants.

The range of ultimate analyses of the liquid organic extractant derivedfrom the liquid organic by-products of the oxo or oxyl process,optionally in admixture with light liquid hydrocarbon fuel if any isshown in Table II. The elements may be taken from the ranges shown solong as the total wt. % is 100.

                  TABLE II                                                        ______________________________________                                        ULTIMATE ANALYSIS OF LIQUID                                                   ORGANIC EXTRACTANT                                                            Derived From Liquid Organic By-Products of Oxo                                or Oxyl Process Plus Light Liquid Hydrocarbon Fuel If Any                                 Wt. %                                                             ______________________________________                                        Carbon        About 55 to 90                                                  Hydrogen      About 5 to 17                                                   Oxygen        About 3 to 40                                                   ______________________________________                                    

The composition of a typical mixture of liquid organic by-products of anoxo process for the production of butyraldehyde, as produced for exampleby the process shown in Hydrocarbon Processing, Page 211, November 1969,Gulf Publishing Co., Houston, Tex. is shown in Table III.

                  TABLE III                                                       ______________________________________                                        Composition of Typical Mixture of Liquid                                      Organic By-Products From Oxo Process                                                             Wt. %                                                      ______________________________________                                        Esters                   54                                                   Ethers                   20                                                   Aldehydes                5                                                    Ketones                  5                                                    Acids         About      5       and below                                    Saturated hydrocarbons                                                                      About      1       and below                                    Olefins       About      1       and below                                    n-butyl alcohol          3.4                                                  i-butyl alcohol          0.6                                                  Alcohol (C.sub.5 -C.sub.8)                                                                             3.0                                                  Water                    2                                                    ______________________________________                                    

The esters in the aforesaid typical mixture have an average carbonnumber of 12 and are formed by the reaction of C₄ to C₉ alcohols and C₃to C₈ acids. The ethers are highly branched and have an average C₁₂number. The ketones have an average C₁₂ number, and the acids have a C₃-C₅ number. The ultimate analysis of said typical mixture is shown inTable IV.

                  TABLE IV                                                        ______________________________________                                        Ultimate Analysis of Typical Mixture of Liquid                                Organic By-Products From Oxo Process                                                       Wt. %                                                            ______________________________________                                               Carbon  69.2                                                                  Hydrogen                                                                              12.0                                                                  Oxygen  18.8                                                           ______________________________________                                    

Other properties of said typical mixture are shown in Table V.

                  TABLE V                                                         ______________________________________                                        Properties of Typical Mixture of Liquid                                       Organic By-Products From Oxo Process                                          ______________________________________                                        Gravity, °API 29.2                                                     Density, grams/cc 0.87                                                        Viscosity, Centistokes at 68° F., 4.15; at 122° F., 2.0         Distillation, ASTM                                                            Vol. %    °F.   Vol. %  °F.                                     IBP       290          60      422                                            10        326          70      450                                            20        344          80      484                                            30        360          90      526                                            40        376          95      532                                            50        396          EP      564                                            ______________________________________                                    

An improved vertical two-stage decanter is used in the subject process.Novel features of the decanter include introducing the feedstreams foreach of the two stages through a sub-assembly comprising two concentriccoaxial pipes that pass through the centrial axial inlet in the upperhead of the decanter, and (2) a means for vertically adjusting, up ordown, the feed conduit and horizontal radial nozzle which are used tointroduce the second stage liquid organic extractant into the decanterabove the interface level.

The drawing shows a decanter with an elongated vertical cylindricallyshaped body having top and bottom heads, an outlet in the bottom headfor the continuous and simultaneous removal of separated water, and aflanged upper central coaxial vertical cylindrical inlet whose diameteris smaller than the diameter of the vessel. The upper central inlet iscentrally located in the top head of the vessel.

The separate conduits through which the feedstreams are continuouslyintroduced pass down through the upper central inlet. An upperhorizontal outlet is located in the vertical side wall of the upperflanged central inlet. A dispersion of soot and co-extractants iscontinuously and simultaneously removed through the upper horizontaloutlet. The decanter may have other geometric forms whose horizontalcross sections are circular. Other shapes for example include: avertical cylinder with a conical top section, a vertical cylinder withan axial cylindrical dome of smaller diameter in tandem, and a sphericalshaped vessel.

Each separate feedstream is continuously and simultaneously distributedhorizontally within the vessel by means of an upper and a lowerhorizontal radial nozzle. The velocity of the liquid feed passingthrough each horizontal radial nozzle may be in the range of about 0.10to about 2.00 feet per second while the velocity of the feed passingthrough the inner and outer vertical feed pipes may be in the range ofabout 0.5 to 10 feet per second. The superficial vertical velocities ofthe separating phases may be on the order of about 0.1 to 2.0 feet perminute so as to allow phase separation with only gentle mixing withinthe upper layer. Each horizontal radial nozzle comprises two paralleldiscs of equal diameter which are separated by a plurality of radialfins. The radial fins also distribute the liquid charge to the decanterin a uniform 360° pattern.

The upper disc of the lower horizontal radial nozzle that is used todistribute the first stage feed mixture of soot, water and first stageextractant within the decanter has a central axial hole. The lower discis solid. The first stage feed mixture is passed into the decanterthrough a straight inner conduit i.e. pipe. The inner conduit passesdown through the central axial inlet in the upper head of the decanter.It then passes down along the central longitudinal axis of the decanterto a point below the interface level. The open downstream end of theinner conduit passes through the central axial hole in the upper disc ofthe lower horizontal radial nozzle. The outside of the inner conduit isattached to the upper disc so that the first stage feed mixture may bedischarged through the lower horizontal radial nozzle and below theinterface level in the lower half of the vessel. The inner conduit andattached lower horizontal radial nozzle do not have a vertical adjustingmeans, such as that provided for the outer conduit and attached upperhorizontal radial nozzle. The lower horizontal radial nozzle may belocated from about 15 to 24 inches, such as 18" , below the interfacelevel. The best location may be determined by trial and error and is afunction of such parameters as Oil Absorption No., residence time, andtemperature and flow rates of the streams, simultaneously entering andleaving the decanter.

Both the upper and lower discs of the upper horizontal radial nozzlethat is used to distribute the second stage liquid organic extractantabove the interface level in the decanter have central axial holesthrough which the inner conduit freely passes. A coaxial concentricouter conduit or straight pipe surrounds the inner pipe along a portionof its length. The inner and outer pipes are radially spaced from eachother to provide an annular passage through which the second stageliquid organic extractant is passed. The upstream end of the annularpassage is provided with a spacing ring, gasket and a retainer ringwhich is attached to the outer pipe for example by screws, threading orwelding. This structure helps to maintain the radial distance betweenthe outside surface of the inner pipe and the inside surface of theouter pipe while providing a seal at the upstream end of the annularpassage which prevents liquids from leaking past while allowing theouter pipe to move or slide vertically up or down with respect to theinner pipe whose vertical movement is fixed.

The outer conduit passes through the central axial inlet in the upperhead of the decanter. The open downstream end of the outer pipe passesthrough the central axial hole in the upper disc of the upper horizontalradial nozzle and is attached to said upper disc so that said annularpassage is in communication with the upper horizontal radial nozzle. Thebottom plate of the upper horizontal radial nozzle has a central axialhole which is slightly larger than the outside diameter of the innerconduit which passes therethrough. This bottom plate helps to maintainthe radial distance between the inner and outer conduits at thedownstream end of the annular passage. The upper horizontal radialnozzle may be located from about 6 to 24 inches, such as 12 inches abovethe interface level. The best location may be determined by trial anderror and is a function of such parameters as temperature and flow ratesof the streams simultaneously entering and leaving the decanter, andresidence time.

Any suitable adjusting means may be provided to move the outer conduitand upper horizontal radial nozzle up or down along the centrallongitudinal axis of the decanter. For example, as shown in the drawingthe adjusting means may comprise the threaded portion of the outsidesurface of the outer conduit that is engaged with the threaded portionof the hub of a rotatable wheel. Alternatively, the adjusting means maycomprise a straight rack with teeth on the top face for gearing with arotatable pinion or worm gear. For example, the back of the rack may beattached longitudinally down the outside of the outer pipe. By thismeans, the outer pipe and upper horizontal radial nozzle may be moved upor down by rotating a hand or motor driven pinion gear which engages theteeth of the rack.

A vertical coaxial concentric cylindrically shaped outer sleevesurrounds the outer conduit where it passes through the upper flangedcentral axial inlet. Mating flanges and a ring gasket seal the sleeve atits upper end. A spacing ring, gasket, and a retainer ring help tomaintain the radial distance between the outside surface of the outerpipe and the inside surface of sleeve while providing a liquid-tightseal at the downstream end of the annular passage between the sleeve andthe outer conduit. The retainer ring is attached to the bottom of thesleeve for example by screws, threading or welding. Liquids are therebyprevented from leaking past the seal while the outer conduit ispermitted to freely move or slide vertically up or down with respect tothe fixed sleeve. A portion of outer conduit has an enlarged diameterwhich is in slidable contact with the inside surface of the outersleeve. The enlarged portion of outer pipe 173 in the drawing may slideup or down within the sleeve, when vertical adjustment of the outerconduit is required. This enlarged portion also serves as an adidtionalradial spacing means between the inside surface of the sleeve and theoutside surface of the outer conduit. Optionally, an additional gasketand a retainer ring may be attached to the bottom of said enlargedportion by screws or threads to provide additional protection againstleaks.

DESCRIPTION OF THE DRAWING

A more complete understanding of the invention may be had by referenceto the accompanying drawing which illustrates a preferred embodiment ofthe invention.

Although the drawing illustrates a preferred embodiment of theinvention, it is not intended to limit the subject invention to theparticular apparatus or materials described.

Referring to FIG. 1, gas generator 1 is a vertical cylindrically shapedunpacked free-flow non-catalytic steel pressure vessel lined withrefractory 2. Annulus-type burner 3 is mounted in upper inlet 4 forintroducing the reactant feedstreams into reaction zone 5.

Burner 3 includes central passage 10, through which a stream offree-oxygen containing gas from line 11 is introduced, and annularpassage 12 through which a mixture of hydrocarbonaceous fuel and astream of temperature moderator, such as steam from line 13 isintroduced. Fresh liquid hydrocarbonaceous fuel feed in line 14 ispassed through lines 15-16 and into fuel charge and mixing tank 17. Intank 17, the fresh liquid hydrocarbonaceous fuel is mixed with at leasta portion of the recycled liquid dispersion of soot and extractants fromline 19. For example, the extractant material may comprise naphtha,liquid organic by-products from an oxo or oxyl process, and mixturesthereof. The fuel feed mixture in tank 17 is passed through lines 24-25and mixed in line 13 with a temperature moderator from line 26, valve27, and line 28 and/or steam from gas cooler 29 by way of lines 30-31,va1ve 32, and lines 33 and 25. Optionally, a portion of the by-productsteam may be passed through line 34, valve 36, and line 35 for useelsewhere in the system or for export. Fresh boiler feed water (BFW)enters gas cooler 29 through line 40.

The raw effluent gas stream from reaction zone 5 may be split into twogas streams in chamber 41. The two gas streams in passages 42 and 43 maybe simultaneously processed downstream and separately cooled, cleanedand scrubbed with water to remove entrained soot. Alternatively, thesystem may be operated with all of the effluent gas streams being passedthrough either passage 42 or 43.

The hot gas stream in passage 42 is passed through dip-tube 44 andquenched in water 45 contained in the bottom of quench tank 46. Arecycle stream of water, to be further described, is introduced intoquench tank 46 via line 47. The quenched gas leaves through line 48 andis scrubbed again in nozzle scrubber 49 before passing through diptube50 into water 51 contained in the bottom of gas scrubber 52. The gasstream then passes up through shower 53 where it is contacted with waterbefore leaving through line 54 at the top of gas scrubber 52 as a cleanstream of product synthesis gas saturated with water. Nozzle scrubber 49may be fed with recycle water from the bottom of gas scrubber 52 by wayof lines 55-56. Scrubbers 49 and 52 may be fed with water from lines 57and 58, respectively. Accumulations of solid materials, such assolidified ash, unconverted carbon and bits of refractory may bewithdrawn from time to time as required through clean-out line 60, valve61 and line 62.

Most of the unreacted carbon i.e. soot leaving the gasifier by way ofline 42 is removed when the gas stream is quenched in water 45. A streamof soot-water dispersion from the bottom of quench tank 46 is passedthrough line 70 and mixed in line 71 with a stream of soot-waterdispersion from line 72. The latter stream of soot-water is obtained byscrubbing the second split stream of hot raw synthesis gas from line 43with water after the gas stream is cooled by indirect heat exchange withBFW in gas cooler 29. Thus, the cooled stream of raw synthesis gas inline 73 is quenched and scrubbed with water 74 in conventional gasscrubber 75 and leaves through line 76 at the top. The gas stream iscooled below the dew point in gas cooler 77. Separation of water 78takes place in separating tank 79, and a clean dewatered stream ofproduct synthesis gas leaves through overhead line 80.

Scrubbing water for gas scrubbers 52 and 75 may be provided throughlines 81 to 83 and 81 and 84 to 86, respectively. The scrubbing watermay comprise degassed water from line 81; fresh make-up water from line87, valve 88, and line 89; and mixtures thereof.

The soot-water dispersion in line 71 and a portion of first stage liquidorganic extractant, for example, naphtha from lines 94-95, valve 96 andlines 97-98 are mixed together in line 99 and by in-line mixer 100. Insuch case valves 101 and 93 are closed. However, in the embodiment ofthe process wherein naphtha is used as both feed to the gas generatorand as the first stage extractant, the fresh liquid hydrocarbonaceousfuel feed in line 14 is naphtha. In such case, valve 101 is open, valves93 and 96 are closed, and the naphtha is passed to mixer 100 by way oflines 14, 103, 104, 98 and 99.

The first stage mixture of soot-water and naphtha passes into decanter110 by way of line 111, and conduit sub-assembly 114 comprising inlet174, central conduit 113, and lower horizontal radial nozzle 115. Alsoincluded in conduit sub-assembly 114 is outer conduit 173 with attachedhorizontal radial nozzle 126, outer sleeve 196, and a means foradjusting outer conduit 173 vertically up or down. Sub-assembly 114passes down through upper flanged central axial inlet 112. Its verticalcentral axis is coaxial with the central axis of the decanter. Themixture is discharged through horizontal radial nozzle 115 located belowinterface level 116. Simultaneously, with valve 93 closed and valve 117open, the second stage liquid organic extractant comprising for examplea mixture of the liquid organic by-products from an oxo or oxyl processis introduced above the interface level 116 by way of lines 118-120,flexible conduit 121, inlet 122, annular passage 125 in sub-assembly 114(see FIG. 2), and is then discharged through upper horizontal radialnozzle 126 and above interface level 116. During operation, decanter 110is completely filled with liquid.

In the decanter, in the preferred embodiment, a dispersion of soot,naphtha, and second stage liquid organic extractant, such as a mixtureof liquid organic by-products from an oxo or oxyl process forms in theupper portion 127 of the decanter and floats on water 128 which settlesout by gravity below. In another embodiment, with valve 117 closed andvalve 93 open, naphtha from line 94 may be introduced as the secondstage extractant by way of lines 129, 130, 120 and 121.

The separated water is passed through vortex breaker 131, bottom outlet132, line 133, pressure reducing valve 134, line 135, and flashed intoflash column 136. A stream of sulfur containing gaseous impuritiesleaves through line 137 and is sent to a Claus unit for sulfur recovery.Alternatively, the gas stream may be flared. By means of valves 140 and141, at least a portion of the degassed water in line 142 may be pumpedby means of pump 143 through lines 144 and 81 and then through theconnecting lines into quench tank 46 and gas scrubbers 49 and 52 and/or75. The remainder of the water, if any, may be sent to a water treatmentfacility by way of line 145, valve 141, and line 146.

At least a portion of the dispersion of soot, naphtha, and mixture ofliquid organic by-products from an oxo or oxyl process in the uppersection 127 of decanter 110 is passed continuously through upper outlet147, and lines 18, 19, 16 and into charge and mixing tank 17. Theremainder, if any, of the soot dispersion in line 18 may be removedthrough lines 20, valve 21, and line 22 and used externally for example,as fuel.

Other elements of the vertical decanter include normally closed bottomdrain outlet 148, side clean out outlet 149, support legs 150,groundpads 151, cylindrical shell body 152, upper head 153, and lowerhead 154. Nine trycocks 160 in spaced vertical alignment pass throughthe wall of the body from below mid-point to near the top. By this meansliquid samples may be taken at various levels. Location of the interfacelevel may be thereby determined. Conventional liquid-level indicatorsmay be used in conjunction with the trycocks.

An enlarged vertical cross-section of conduit sub-assembly 114 mountedin decanter 110 is shown in FIG. 2. Sub-assembly 114 passes down throughupper flanged central axial inlet 112 and along the central verticalaxis of decanter 110. Inlet 112 is located in upper head 153 and isprovided with side outlet 147 and circular flange 168. Flange 168 isprovided with central axial hole 169, counter bore 170; and a pluralityof bolt holes 171.

Sub-assembly 114 includes concentric outer pipe 173 and inner pipe 113along with the means for the longitudinal adjustment of outer pipe 173.Any suitable conventional supporting means may be used for holding innerpipe 113 in a fixed vertical position, thereby preventing itslongitudinal movement. For example, brackets or bracing means (notshown) may project upwardly from the upper portion of decanter 110 torigidly hold inner pipe 113 near its upper end. By such means, allmovement of inner pipe 113 may be prevented. For example, pipe 113 maybe secured to brackets by supporting band 105, threaded rod 106,turnbuckle 107, and threaded rod 108. Annular passage 125 is locatedbetween the outside diameter of pipe 113 and the inside diameter of pipe173. Upper inlet 174 is attached to the upper end of inner pipe 113 andis used to introduce a mixture of soot, water and first-stage liquidorganic extractant. This mixture flows down through pipe 113 and isdischarged through lower horizontal radial nozzle 115 into verticalcylindrical decanter 110 below the interface level 116. Radial nozzle115 comprises upper annular disc 175 and lower disc 176. Upper disc 175is welded at right angles to the downstream open end of pipe 113. Bottomsolid disc 176 is held parallel to disc 175 by a plurality of radiallydirected spacers 177. Spacers 177 separate discs 175 and 176 and alsodirect the liquid being discharged through radial nozzle 115 in a 360°flow pattern.

Annular passage 125 is closed at the upper end by annular packingretainer plate 180, packing 181 such as an O-ring, and top annular plate182. Packing 181 is pressed between plates 180 and 182 to provide aleak-proof seal while permitting the slidable adjustment of pipe 173 upor down. Plates 180 and 182 are attached to pipe 173 and also help tomaintain the spacing of annular passage 125. The second stage liquidorganic extractant, such as a mixture of the liquid organic by-productsfrom an oxo or oxyl process, is passed through upper inlet 122 near theupstream end of outer pipe 173 and into annular passage 125. The liquidextractant flows down through annular passage 125 and is dischargedthrough upper horizontal radial nozzle 126 and into decanter 110, abovethe interface level 116. Radial nozzle 126 comprises upper annular disc184 and lower annular disc 185. Upper annular disc 184 is welded atright angles to the downstream open end of pipe 173. Bottom annular disc185 is held parallel to disc 184 by a plurality of radially directedspacers 186. These spacers also direct the discharge of the liquidorganic extractant through radial nozzle 126 in a 360° flow pattern.

A portion of pipe 173 extending below inlet 122 is provided withexternally threaded section 190 followed by straight portion 191 havingan increased outside diameter. Concentric, coaxial cylindrical shapedsleeve 196 surrounds outer pipe 173 and inner pipe 113 along thoseportions of these pipes which pass through and which may extend a littlebeyond upper inlet 112. The outside diameter of the straight portion 191of pipe 173 having an enlarged outside diameter is in slidable contactwith the inside diameter of sleeve 196. Optionally, the downstream endof straight portion 191 may be provided with a circular groove to holdgasket 192, such as an O-ring. Gasket 192 is pressed between the bottomof straight portion 191 and a retainer ring 195 which is attached topipe 173. A supplemental leak-proof seal is thereby provided at thedownstream end of straight portion 191 while permitting the slidableadjustment of straight portion 191 up or down within concentric outersleeve 196.

Sleeve 196 is open at the upstream end through which pass saidconcentric pipes 113 and 173. It is also provided with a disc shapedannular shoulder 197 which extends perpendicular to the outside diameterof sleeve 196 below the upstream end. Shoulder 197 fits into counterbore 170 in flange 168. The portion of sleeve 196 below shoulder 197passes through central hole 169 in flange 168. i Annular passage 200 isprovided between the outside diameter of pipe 173 and the insidediameter of sleeve 196. Annular passage 200 is closed at the downstreamend by annular packing retainer plate 201, packing 202 such as anO-ring, and bottom annular plate 203. Packing 202 is pressed betweenplates 201 and 203 to provide a leak-proof seal while permitting theslidable adjustment of pipe 173 up or down within concentric sleeve 196.A sliding fit is provided between the outside diameter of pipe 173 andthe inside diameters of annular plates 201 and 203. Plates 201 and 203are attached to sleeve 196 and also help to maintain the spacing ofannular passage 200.

Top circular flange 205 has a central axial hole 206, and a plurality ofbolt holes 207 that match holes 171 in flange 168. Annular shaped gasket208 is positioned on the upper surface of horizontal flange 168.Horizontal top flange 205 is then assembled over flange 168 so that theportion of sleeve 196 extending above shoulder 197 passes through thecentral hole in gasket 208 and through hole 206 in top flange 205. Boltholes 207 and 171 are lined up and flanges 205 and 168 are then boltedtogether.

Coaxial concentric wheel 209 with threaded hub 210 engaging threadedsection 190 of pipe 173 is mounted on the upper surface of flange 205 sothat outer pipe 173 may be freely raised or lowered vertically along thecentral axis of decanter 110 by rotating wheel 209. Clamp 211 is boltedto flange 205. Wheel 209 is secured by a portion of clamp 211 engagingcircumferential groove 212 in the side of hub 210. By this means wheel209 is rotatably mounted on the upper surface of flange 205 while thevertical movement of hub 210 is restricted. Other conventional securingmeans may be employed, including the use of ball bearings.

EXAMPLE

The following example illustrates a preferred embodiment of the processof this invention as related to FIG. 1 of the drawing. The exampleshould not be construed as limiting the scope of the invention. Theprocess is continuous and the flow rates are specified on an hourlybasis for all streams of materials.

15,000 lbs. of soot-water dispersion containing 150 lbs. of soot from aquench tank and soot scrubbing unit used to quench cool and clean astream of 451.8 thousand standard cubic feet (SCF measured at 60° F. and1 atm.) of raw synthesis gas (dry basis) are mixed with 1,050 lbs. ofnaphtha.

The synthesis gas is produced in a free-flow non-catalytic partialoxidation gas generator by the partial oxidation of 9,629 lbs. of afeedstream from a fuel charge and mixing tank comprising a mixture ofthe following in lbs: heavy fuel oil 3,629, a dispersion of soot andliquid organic co-extractants comprising soot 150, naphtha 1,050 andliquid organic by-products from an oxo process 4,800. The specificgravity of the feedstream is 0.875, degrees API is 30.0, gross heatingvalue is 17,280 BTU/lb. and the Ultimate Analysis in weight % follows: C77.90, H 11.73, N 0.26, S 0.75, O 9.34 and ash 0.02. The feedstream isreacted at a temperature of 2,110° F. and a pressure of 1,000 psig with8,476 lbs. of a free-oxygen containing gas comprising 99.5 mole % O₂ and3,852 lb. of steam. The composition of the raw synthesis gas leaving thegas generator in mole % follows: CO 38.91, H 42.98, CO₂ 4.93, H₂ O10.88, CH₄ 1.96, Ar 0.10, N₂ 0.07, H₂ S 0.16 and COS 0.01. Entrained inthe hot effluent gas stream is 2.0 weight percent of unconverted carbon(basis weight % of carbon in hydrocarbonaceous feed to gas generator).

In the process, the aforesaid mixture of soot-water dispersion is mixedwith the 1,050 lbs. of naphtha at a temperature of 200° F. The mixtureis introduced into a vertical decanter, as shown in the drawing, belowthe interface level. Simultaneously, the 4,800 lbs. of liquid organicby-products of an oxo process having an ultimate analysis as shown inTable IV and at a temperature of about 200° F. are introduced into thevertical decanter above the interface level as the second stageextractant. Simultaneously, about 14,850 lbs. of clarified water areremoved from the bottom of the decanter. After degassing, the water isrecycled to the gas quench tank and/or scrubbing unit. Simultaneously,the 6,000 lbs. of soot-coextractant dispersion are removed from the topof the decanter at a temperature of about 200° F. and are recycled tosaid fuel charge and mixing tank. There, the dispersion is mixed withthe aforesaid heavy fuel oil prior to being introduced into the gasgenerator, as previously described.

The process and apparatus of the invention have been described generallyand by example with reference to materials of particular compositionsfor purposes of clarity and illustration only. It will be apparent tothose skilled in the art from the foregoing that various modificationsof the process and apparatus and materials disclosed herein can be madewithout departure from the spirit of the invention.

We claim:
 1. In a continuous process for producing cool and cleansynthesis gas, fuel gas or reducing gas comprising reacting ahydrocarbonaceous fuel with a free-oxygen containing gas in the presenceof temperature moderator in a free-flow noncatalytic partial oxidationgas generating zone to produce a hot effluent gas stream comprising H₂,CO, CO₂, soot, and at least one gas from the group H₂ O, H₂ S, COS, CH₄,N₂ and Ar; quench cooling and scrubbing with water and/or cooling in agas cooler and scrubbing with water said effluent gas stream to coolsaid effluent gas stream and to remove at least a portion of said soot,thereby producing a dispersion of soot and water; the improvementcomprising: (1) mixing a first liquid organic extractant which issubstantially immiscible with water and comprising a light liquidhydrocarbon fuel having an atmospheric boiling point in the range ofabout 100° F. to 700° F., degrees API in the range of over 20 to about100, and a carbon number in the range of about 5 to 16 with saidsoot-water dispersion in the amount of about 1.5 to 15 lbs. of saidfirst liquid organic extractant per lb. of soot so as to render saidsoot hydrophobic and to release dry-appearing powdered soot from saidsoot-water dispersion, thereby producing a liquid feed mixture of soot,water and first liquid organic extractant; and separating said liquidfeed mixture by gravity into a clarified water layer and a sootdispersion in a closed vertical cylindrical decanter vesselsubstantially filled with liquid, and wherein said soot dispersionfloats on said clarified water layer at the interface level; whereinsaid liquid feed mixture is continuously introduced into said vessel byway of a vertical conduit which is coaxial with the central verticalaxis of said vessel and then through a communicating first horizontalradial nozzle located below the interface level and with said radialnozzle uniformly distributing said feed 360°, and wherein thetemperature in said vessel is in the range of about 200° F. to 650° F.and the pressure is high enough to keep said liquid organic extractantin liquid phase; while (2) simultaneously and continuously introducing asecond separate liquid organic extractant comprising a mixture of liquidorganic by-products from an oxo or oxyl process and having the followingultimate analysis in weight %: carbon 55 to 90, hydrogen 5 to 17, andoxygen 3 to 40, into said vessel by way of conduit means which iscoaxial with the central vertical axis of said vessel and then through acommunicating second horizontal radial nozzle located above saidinterface level and which uniformly distributes the second extractant360°; and said second liquid organic extractant is introduced into saidvessel to float off the soot from the surface of the bottom water layerwhile forming dispersion of soot and co-extractants having a sootcontent in the range of about 0.5-9.0 weight percent; (3) simultaneouslyand separately removing a continuous stream of said separated water froman outlet in the bottom of said vessel and a continuous stream of saiddispersion of soot and co-extractants from an outlet in the top of saidvessel; (4) recycling at least a portion of said clarified water, withor without purification, to said gas quench cooling and/or scrubbingoperations to cool and/or scrub said effluent gas stream and to producesaid dispersion of soot and water; and (5) recycling at least a portionof said dispersion of soot and co-extractants to the partial oxidationgas generating zone as at least a portion of the feedstock.
 2. Theprocess of claim 1 wherein said second liquid organic extractantcomprises at least one alcohol, at least one ester, and at least oneconstituent from the group consisting of aldehydes, ketones, ethers,acids, olefins, saturated hydrocarbons, and water.
 3. The process ofclaim 1 wherein said first liquid organic extractant is a light liquidhydrocarbon fuel selected from the group consisting of butane, pentane,hexane, toluol, gasoline, naphtha, and gas oil.
 4. The process of claim1 wherein said second liquid organic extractant comprises the followingmixture:

    ______________________________________                                        Group           Carbon Range  Wt. %                                           ______________________________________                                        Alcohols        C.sub.3 to C.sub.16                                                                         2 to 75                                         Esters          C.sub.6 to C.sub.28                                                                         5 to 70                                         Aldehydes       C.sub.3 to C.sub.16                                                                         Nil to 25                                       Ketones         C.sub.3 to C.sub.16                                                                         Nil to 25                                       Ethers          C.sub.6 to C.sub.28                                                                         Nil to 50                                       Acids           C.sub.3 to C.sub.16                                                                         Nil to 10                                       Olefins         C.sub.5 to C.sub.15                                                                         Nil to 30                                       Saturated Hydrocarbons                                                                        C.sub.5 to C.sub.28                                                                         Nil to 15                                       Water                         Nil to 15                                       ______________________________________                                    


5. The process of claim 1 wherein the velocities of the streams passingthrough the said first and second horizontal radial nozzles are in therange of about 0.10 to about 2.0 feet per second, and the verticalvelocities of separating phases are in the range of about 0.1 to 2.00feet per minute.
 6. The process of claim 1 wherein said second liquidorganic extractant is a by-product from an Oxo process and has thefollowing composition:

    ______________________________________                                                       Wt.%                                                           ______________________________________                                        Esters           54                                                           Ethers           20                                                           Aldehydes        5                                                            Ketones          5                                                            Acids            About 5 and below                                            Olefins          About 1 and below                                            Saturated hydrocarbons                                                                         About 1 and below                                            n-butyl alcohol  3.4                                                          i-butyl alcohol  0.6                                                          Alcohol (C.sub.3 -C.sub.8)                                                                     3.0                                                          Water            2                                                            ______________________________________                                    